Carton



y 1935. J. L.V,BAYLIESIS 2,000,210

CARTON Filed Dec. 8, 1933 Patented May 7, 1935 CARTON John L. Bayless, Anchorage, Ky., assignor to Jefferson Island Salt Company, Louisville, Ky., a corporation of Kentucky Application December 8, 1933, Serial No. 701,528 I 7 Claims. (Cl. 229-17) This invention relates to cartons or boxes, and more particularly to containers of polygonal cross section that are made from unitary blanks of foldable material.

One of the objects of the present invention is to provide a carton of novel construction and improved characteristics which may be formed from a unitary piece of foldable material, the carton blank being readily susceptible of die production and its elements being easily foldable into proper relation to form the complete carton.

Another object is to provide a carton of hexagonal cross-section which may be easily and economically formed from a novelly shaped, unitary blank of foldable material.

It is contemplated that one of the uses to which the present invention is applicable is as a container for finely divided materials such as salt, sugar, cereals, and the like. has been experienced in the past in packaging materials of this character because of their tendency to sift or leak out of their containers, particularly at the edges thereof adjacent the top and bottom end closures. It is therefore a further object of the invention to provide a carton of improved construction for containing finely divided material wherein a continuous covering is provided for every external edge of the carton and the latter is rendered substantially leak-' proof.

Still another object is to provide a carton of this character which also includes novel means for dispensing or emptying the contents thereof without the necessity for tampering with the adhesive engagement of the closure flaps.

In my Patent No. 1,909,649, issued May 16, 1933, there is disclosed a carton capable of ful filling the foregoing objects in a generally satisfactory manner. .However, it has been found thatthe .form of cartonblank therein disclosed is not readily handled in a completely efficient manner by the package machinery now ava lable, particularly with respect to the closing and sealing of the carton top after filling. Accordingly, it is one of the principal objects of the present invention to provide a carton of polygonal, and preferably hexagonal, shape which is made from a single blank of foldable material of novel construction and wherein the end closures are formed by a pluralityof flaps of-such shape, and foldable in such a manner, that the closing and sealing operations are readily and efliciently performable by automatic machinery.

Still another object is to provide a polygonal carton of improved construction wherein the end However, difiiculty closures are formed by a plurality of inner, outer,

and intermediate flaps, the inner flaps being which may be quickly and easily folded and sealed to one another to form a polygonal carton of the character described.

These and other objects will appear more fully from a consideration of the detailed descriptionof the invention which follows. Although only one embodiment of the invention has been described and illustrated in the accompanying drawing, it is to be expressly understood that this drawing is for the purpose of illustration only and is not to be construed as a limitation of the scope of the invention, reference being had for this purpose to the appended claims.

In the drawing: Fig. 1 is a plan view of one form of blank from which a carton may be constructed in accordance with the present invention; and

Fig. 2 is a perspective view of a carton made from the blank of Fig. 1 with the top end closure only partially completed.

Referring now to the drawing, wherein like reference characters indicate like parts throughout both the views, there is disclosed therein a unitary carton blank of novel shape, the various elements of the blank being readily foldable by automatic machinery to form the complete carton and constituting when sealed a substantially leakproof container. As shown, the carton'is preferably formed from a unitary blank, indicated generally at 3, of any suitable foldable material such as cardboard, having a substantially rectangular body portion suitably .scored transversely along the lines 4, 5y 6, l, 8 and 9 in order toform a plurality of panels [0, ll, l2, l3, l4 and I5 which form the sides of the carton when it is assembled, and a securing or pasting strip or flap 16, adjacent end panel 15, which is adapted to be coated with suitable adhesive and secured thereby to the inner surface of the opposite end flap II] when the carton is formed. In the embodiment illustrated, the body portion ofthe' blankincludes six rectangular panels of equal size for forming a carton havingfla hexagonal cross-section, but it will be understood thatjthe invention is not limited to hexagonal cartons, not

to cartons having rectangular sides, nor even to sides all of the same size.

In addition to the body portion comprising the panels forming the sides of the carton, blank 3 is also provided with suitable appendages in the form of flaps which are adapted to form the end closures of the carton and when folded and sealed render the latter substantially leak-proof. In the form shown, one of the panels intermediate end panels l and I5, such as panel I3, is scored at its extremities as indicated at H and I8, beyond which score lines said panel is provided with a pair of end flaps I3 and 20. In the embodiment illustrated, end flaps l9 and 20 are hexagonal in shape and substantially equal in area to the cross-section of the assembled carton, and are adapted to form'the outer portions of the end closures. One of the other panels,

preferably panel which is opposite to panel,

l3 when the carton is assembled, is similarly scored at 2| and 22 and provided with a pair of end flaps 23 and 24. As shown, end flaps 23 and 24 are also hexagonal in shape but are made slightly smaller in area than the inner dimensions of the assembled carton, and are adapted to form the inner portions of the end closures. By making inner closure flaps 23 and 24 slightly smaller than the inside dimensions of the carton, the free edges and corners of these flaps, when in folded position, engage the inner surfaces and corners of the side panels of the carton adjacent the end edges thereof so as to brace the carton from within and maintain its shape during the time that the remainder of the flaps are being folded and adhesively secured to one another.

In addition to the inner and outer end closure flaps just described, suitable means have also been provided for furnishing the carton with intermediate flaps, one of the important functions of which is to insure a thoroughly tight, leakproof container especially well adapted for containing finely divided materials. In the embodiment shown, all of the panels of the body portion of blank 3, other than the two panels to which the inner and outer hexagonal flaps are secured, are provided at each end with polygonal flaps of relatively smaller size which, when folded into proper relation when the carton is assembled, provide continuous coverings for every end edge of said panels. As shown, panels ll, l2, l4 and are suitably scored at their extremities as indicated-at 25, 26, 21, 28, 29, 30, 3| and 32,

and are extended to provide intermediate flaps These flaps are preferably triangular in shape, of equal area and' 33, 34, 35, 36, 31, 38, 39 and 40.

each substantially equal to one-sixth of the area of hexagonal flaps 23 and 24. Consequently, when the intermediate triangular flaps are folded on top of inner hexagonal flaps 23 and 24 they do not overlap and cover only approximately twothirds of the area of said inner flaps, leaving uncovered substantially triangular portions indicated at 4| and 42 in Fig. 2.

It will be noted that with the construction thus described, every side panel is provided with a pair of closure flaps extending from the opposite extremities thereof so that when all of the flaps are folded and sealed there is provided a carton in which every external edge is provided with a complete continuous covering, leaving no cracks through which the material with which the carton is filled may escape. Also, by so constructing the intermediate flaps that they do not overlap when folded, the folding operation is simpliiied and a neat, compact end closure provided.

In forming a carton from the blank thus described, the blank having previously been cut or die-stamped from a single piece of material and suitably scored as indicated in the drawing, folds are first made along score lines 4, 5, 6, I, 8 and 3, and pasting flap I6 is coated with a suitable adhesive and secured thereby to the inner surface of panel I, thereby forming the body portion of the carton.

Folds are then made along lines 2| and 22, and the inner hexagonal flaps 23 and 24 are folded in to the position indicated in Fig. 2. As will be seen from this figure, which shows in detail only the top end closure, the bottom closure being formed in exactly the same manner, the inner hexagonal flaps 23 and 24 fit snugly inside of the body portion of the carton with their free edges and corners engaging the inner surfaces and corners of side panels ll, l2, 13, I4 and I5, thereby bracing the carton body from within and maintaining its shape while the intermediate triangular flaps 33, 34, 35, 3G, 31, 38, 39 and 40, and the outer hexagonal flaps l9 and 20, are folded down and adhesively secured to one another. Folds are then made along score lines 25, 26, 21, 28, 28, 38, 3| and 32 and the intermediate triangular flaps are folded down in non-overlapping relationship on top of inner hexagonal flaps 23 and 24. The outer surfaces of the intermediate flaps may then be coated with a suitable adhesive and/or, if desired, the inner surface of outer hexagonal flaps l9 and may be similarly coated. Finally, outer hexagonal flaps l3 and 20 are folded down along lines I! and I8 on top of and into adhesive engagement with the underlying flaps. When the carton is thus completely sealed, there are no uncovered external edges or cracks through which the contents of the carton may escape. The completely assembled carton may then, if desired, be enclosed in a suitable wrapper, as of waxed paper.

Novel means are also provided for dispensing or removing the contents of the carton without disturbing the adhesive engagement between the closure flaps. In the form shown, inner hexagonal flap 23 is provided with a cutaway portion or opening 43 located in such a position that it is not covered by intermediate flaps 33, 35, 3 1 and 39 when the latter are folded in their assembled position. In the embodiment illustrated, opening 43 is formed in the edge of inner-hexagonal flap 23 opposite to that which is secured to panel l0 and lies in uncovered portion 4| of said flap, as shown in Fig. 2. The corresponding outer hexagonal flap I9 is provided with a suitable readily removable portion 44 so located as to overlay opening 43 in registry therewith when the flaps are in folded position. As shown, removable portion 44 is triangular in shape with its apex directed towards and slightly spaced from the top edge of the carton formed by score line H, the base of said portion being a continuous score line and the two sides being intermittently scored. with this form of scoring, the sides of portion 44 may be cut by a suitable instrument and the triangular piece then turned to and from closed position about the continuously scored base line as a hinge.

The construction thus described provides a convenient. dispensing outlet through which the contents of the carton may be easily emptied, particularly when the carton is used for pourable materials such as salt. It will also be noted that by locating opening 43 in the position shown in the drawing, it is bounded by intermediate flaps 35 and 3| and overlaid by outer hexagonal flap [5, the latter in turn being adhesively secured to said intermediate flaps, so that any material which might escape through opening 43 during handling is confinedto the space immediately overlying uncovered portion ll of inner hexagonal flap 23 and is prevented from leaking out by virtue of the-fact that flaps I9, and 31 form continuous coverings for the external edges of the carton adjacent to said opening.

While in the embodiment illustratedonly one dispensing outlet has been provided, it will be understood that both ends of the carton may be so equipped, if desired.

There is thus provided by the present invention a novel form of box or carton made from a unitary blank of foldable material which is provided with end closures formed by a plurality of inner, outer and intermediate flaps folded and sealed in such a manner as to result in a tight, leak-proof container especially well adapted for containing finely divided materials such as salt and the like. The blank from which the carton is formed comprises a single piece of foldable material of novel shape suitably scored for quick and easy folding into the desired form. Each of the side panels of the carton is provided with closure flaps at either end so that when the latter are folded every external edge of the carton is provided with a complete, continuous covering so as to effectively close all cracks through which the material within the carton might escape. Moreover, the shape of the various flaps and the manner in which they are folded are such as to provide a bracing for the carton and maintenance of its shape during the folding operation, thereby rendering it susceptible of handling by automatic machinery. The carton also embodies novel dispensing means which are so formed as to in no way decrease the leak-proof qualities of the novel arrangement of closure flaps disclosed. The carton thus formed is simple in structure, and inexpensive of manufacture, particularly due to the fact that the novel arrangement of the flaps makes possible efiicient closing thereof by automatic machinery.

It will be obvious that the invention is not limited to the specific form described and illustrated in the accompanyingdrawing, but is capable of a variety of mechanical embodiments. For example, the panels forming the sides of the carton may be of any desired shape and size instead of rectangular and equal as shown, and the flaps may be secured to the panels in any desired arrangement other than that illustrated. Further, the intermediate closure flaps are 'not restricted to triangular shapes, but may be given any desired configuration that will permit them to overlay the inner hexagonal flap in non-overlapping relationship and still provide an uncovered portion wherein the dispensing or pouring opening may be located. Also, it will be understood that a carton may be constructed in accordance with the present invention with a different number of sides than six, and that the inner and outer closure flaps may accordingly vary in cross-section from the hexagonal form shown. Various other changes, which will now appear to those skilled in the art, may be made in the form, details of construction and arrangement of the parts without departing from the spirit of the invention, and reference is therefore to be had to the appended claims for a definition of the limits of the invention.

What is claimed is: a

1. In a polygonal carton, an end closure comprising a polygonal flap of the same shape as but of size slightly smaller than the cross-section of said carton secured to one of the side panels of the carton and forming the innermost portion of said closure, said flap lying within the carton with its free edges and corners so disposed as to brace the carton from within, a second polygonal flap of similar shape secured to another of the side panels of the carton and forming the outermost portion of the end closure, and a plurality of relatively smaller polygonal flaps secured one to each of the remaining side panels and ly-'- ing between said inner and outer polygonal flaps,

than the inner dimensions of said carton secured to one of the side panels of the carton and forming the innermost portion of the end closure, the free edges and comers of said flap engaging the inner surfaces and comers of the side panels of the carton adjacent the end edges thereof and bracing the carton from within, relatively smaller polygonal flaps secured to four other of the side panels of the carton and lying in non-overlapping relationship on top of said inner hexagonal flap, and a second hexagonal flap secured to the remaining panel of the carton and forming the outer portion of the end closure, said outer hexagonal flap overlying both said inner hexagonal flap and all of said smaller polygonal flaps and being adhesively secured to the latter.

3. In a hexagonal carton, an end closure comprising a hexagonal flap of a size slightly smaller than the inner dimensions of said carton secured to one of the side panels of the carton and forming the innermost portion of the end closure, the free edges-and corners of said flap engaging .the inner surfaces and corners of the side panels of the carton adjacent the end edges thereof and bracing the carton from within, relatively smaller polygonal flaps secured to four other of the side panels of the carton and lying on top of said inner hexagonal flap, said polygonal flaps covering less than the entire area of said inner hexagonal flap, and a second hexagonal flap secured to the remaining panel of the carton and forming the outer portion of the end closure, said outer hexagonal flap overlying both said inner hexagonal flap and all of said smaller polygonal flaps and being adhesively secured to, the latter, said inner hexagonal flap having a cutaway portion in the area not covered by said polygonal flaps, a portion of the outer hexagonal flap being scored to provide a emovable piece located in registry with said cutaway portion, said cutaway and scored portions constituting a means for dispensing the contents of the carton.

4. A carton having six side panels and two end closures, each of the latter comprising a hexagonal flap of a size slightly smaller than the inner dimensions of said carton secured to one of the a secured to the remaining side panel and forming the outer portion of the end closure, said outer hexagonal flap overlying both said inner hexagonal flap and all of said smaller polygonal flaps and being adhesively secured to the latter, the inner and outer hexagonal flaps of one of said end closures being provided with overlying cutaway and readily removable portions, respectively, constituting a means for dispensing the contents of the carton.

5. A carton having six side panels and two end closures, each of the latter comprising a hexagonal flap of a size slightly smaller than the inner dimensions of said carton secured to one of the side panels and forming the innermost portion of the end closure, the free edges and corners of said flap engaging the inner surfaces and corners of the side panels adjacent the end edges thereof and bracing the carton from within, a second hexagonal flap secured to the side panel opposite said first-named panel and forming the outer portion of the end closure, and relatively smaller polygonal flaps secured to the four remaining side panels and lying intermediate said inner and outer hexagonal flaps, the inner and outer hexagonal flaps of one of said end closures being provided with overlying cutaway and readily removable portions, respectively, constituting a means for dispensing the contents of the carton, said portions being located adjacent the panel to which said outer hexagonal flap is secured.

6. In a polygonal carton especially adapted for I packaging finely divided materials, an end closure comprising a polygonal flap of the same shape as the cross-section of said carton secured to one of the side panels of the carton and forming the innermost portion of said closure, said flap lying with its free edges below the plane of the end edges of the carton side panels and being of such a size that its said free edges and corners snugly engage the inner surfaces and corners of the carton side panels adjacent the end edges thereof, thereby both bracing the carton from within and minimizing sifting of the material contained in said carton, a second polygonal flap of similar shape secured to another of the side panels of the carton and forming the outermost portion of the end closure, and a plurality of relatively smaller polygonal flaps secured one to each of the remaining side panels and lying in non-overlapping relationship between said inner and outer polygonal flaps, said relatively smaller flaps providing a covering for every external edge of the end of the carton except those to which said inner and outer flaps are secured and being adhesively secured to said outer flap.

7. In a hexagonal carton especially adapted for packaging finely divided materials, an end closure comprising a hexagonal flap secured to one of the side panels of the carton and forming the innermost portion of said closure, said flap lying with its free edges below the plane of the end edges of the carton side panels and being of such a size that its said free edges and corners snugly engage the inner surfaces and corners of the carton side panels adjacent the end edges thereof, thereby both bracing the carton from within and minimizing sifting of the material contained in said carton, a second hexagonal flap secured to another of the side panels of the carton and forming the outermost portion of the end closure, and a plurality of triangular flaps secured one to each of the remaining side panels and lying in non-overlapping relationship between said inner and outer hexagonal flaps, said triangular flaps providing a covering for every external edge of the end of the carton except those to which said inner and outer hexagonal flaps are secured and being adhesively secured to said outer hexagonal flap.

JOHN L. BAY'LESS. 

